Ceramic tile with imitation granite texture and preparation process thereof

Abstract

A ceramic tile with imitation granite texture and a preparation process thereof. The ceramic tile comprises a brick body and a matte glaze surface attached to the surface of the brick body. The brick body comprises the following raw materials: tile waste, calcite, vermiculite, andalusite, sericite, zirconium silicate, aluminum oxide, zinc oxide, and dolomite; the matte glaze surface comprises the following raw materials: matte frit, perlite, quartz stone, kaolin, zirconium oxide, magnesium oxide, iron oxide, manganese oxide, and titanium oxide. By optimizing and adjusting the components and content of the matte glaze layer and combining a special firing process, the fired ceramic tile surface has an off-white base color with dotted or blocky black markings distributed on the base color, so as to be closer to the naturally formed granite texture and color, with an overall beautiful appearance and meeting market demand.

Description

Technical Field

[0001] The invention belongs to the field of ceramic tile preparation, and particularly relates to a ceramic tile with imitation granite texture and a preparation process thereof. Background Art

[0002] Natural granite is often used for outdoor paving. However, natural granite is weak, prone to cracking, exhibits significant color variation, has poor stain resistance, and is not readily available. Furthermore, large-scale mining of granite is environmentally damaging. Consequently, its application is severely limited. Consequently, researchers have developed imitation granite tiles with patterns similar to those of natural granite.

[0003] Imitation granite tiles have the texture and color of natural granite, offering more vibrant and diverse colors than natural granite. Different specifications can also be laid to create a variety of patterns. As a result, they are widely used in plazas, luxury hotels, buildings, gardens, villas, roadside paving, and parking lots, and are increasingly popular in the market. The current production process for imitation granite tiles involves laying out the blanks and color spots in a specific pattern, pressing them into shape, and then firing them. The color spots require a separate formulation of white clay and colorants, which not only increases the process complexity and production cost, but also fails to meet environmental protection requirements and requires further improvement. Summary of the Invention

[0004] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a ceramic tile with imitation granite texture and a preparation process thereof.

[0005] The present invention adopts the following technical solutions:

[0006] A ceramic tile with imitation granite texture, comprising a brick body and a matte glaze attached to the surface of the brick body.

[0007] The brick body comprises the following raw materials in parts by weight: 40-50 parts of tile waste, 8-12 parts of calcite, 6-10 parts of vermiculite, 15-18 parts of andalusite, 5-10 parts of sericite, 3-5 parts of zirconium silicate, 4-7 parts of aluminum oxide, 2-3 parts of zinc oxide, and 3-5 parts of dolomite;

[0008] The matte glaze comprises the following raw materials in parts by weight: 7-8 parts of matte frit, 18-22 parts of perlite, 35-40 parts of quartz stone, 15-20 parts of kaolin, 3-5 parts of zirconium oxide, 6-8 parts of magnesium oxide, 1-3 parts of iron oxide, 2-3 parts of manganese oxide, and 1-2 parts of titanium oxide.

[0009] Furthermore, the chemical composition of the matte frit is as follows: SiO2: 58.34%, Al2O3: 13.67%, CaO: 8.78%, MgO: 6.52%, ZnO: 4.08%, Li2O: 3.12%, K2O: 1.52%, Na2O: 2.17%, Fe2O3: 1.05%, Y2O3: 0.75%.

[0010] Furthermore, the chemical composition of the tile waste is as follows: SiO2: 68.15%, Al2O3: 12.57%, CaO: 6.64%, MgO: 2.11%, ZnO: 7.95%, Na2O: 2.58%.

[0011] Furthermore, the thickness of the brick body is 8-10 mm, and the thickness of the matte glaze layer is 0.5-0.6 mm.

[0012] A process for preparing ceramic tiles with imitation granite textures comprises the following steps:

[0013] Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry;

[0014] Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness;

[0015] Step three: apply the glaze slurry prepared in step one to the surface of the brick. After the glaze slurry is dried, it is sent to a kiln and fired in a reducing atmosphere at a temperature of 1120-1180°C.

[0016] Furthermore, in step 3, the firing control is specifically as follows:

[0017] Low temperature stage: the temperature in the kiln rises from room temperature to 560-600℃, and the kiln is kept warm for 2-3 hours;

[0018] Decomposition and oxidation stage: the temperature in the kiln is raised to 880-920℃ and the kiln is kept warm for 5-6 hours;

[0019] High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1120-1180℃, and the heat preservation and kiln firing time is 10-12 hours;

[0020] Cooling and slow-release stage: the temperature in the kiln is cooled to 720-760℃ at a rate of 2℃ / min, and the kiln is kept warm for 4-6 hours;

[0021] Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

[0022] Furthermore, during wet ball milling of the slurry in step 1, the raw materials are wet ground in a ball mill for 15-18 hours, the grinding medium is water, and the ratio of raw materials: balls: water is 1:1.3-1.5:1-1.5.

[0023] Furthermore, during the wet ball milling of the glaze slurry in step 1, the raw materials are wet ground in a ball mill for 36-42 hours, the grinding medium is water, and the raw material: ball: water = 1:2-2.2:1.5-2.

[0024] It can be seen from the above description of the present invention that, compared with the prior art, the present invention has the following beneficial effects:

[0025] First, by optimizing and adjusting the composition and content of the matte glaze layer and combining it with a special firing process, the fired ceramic tile surface has an off-white base color, with dotted or block-shaped black markings distributed on the base color, which is closer to the texture and color of naturally formed granite, with an overall aesthetic appearance and meeting market demand. Among them, Zhang Hong introduced tile waste as raw material for the brick body to realize the utilization of waste resources, and combined it with sillimanite, calcium silicate and sericite to ensure the strength and wear resistance of the prepared ceramic tile. In the matte glaze surface, zirconium oxide, iron oxide and magnesium oxide are introduced as display agents to form a bluish-white base color. At the same time, manganese oxide is combined with titanium oxide and the firing process to form dotted or block-shaped black markings on the base color.

[0026] Secondly, the chemical composition of the matte frit is specifically defined and combined with other glaze materials to increase the melting temperature of the matte glaze layer and reduce the firing temperature of the matte glaze layer, so that the resulting glaze surface achieves a delicate matte effect that is closer to the color of naturally formed granite.

[0027] Third, the firing process of the matte glaze layer is specifically limited, and the specific parameters of the high-fire reduction and heat preservation stage and the cooling and slow-release stage are strictly controlled to ensure that the glaze surface does not smoke and turn yellow, and the glaze surface presents a grayish-white base color. In addition, the cooling and slow-release stage is added to reduce the internal stress of the glaze layer after high-temperature firing, so that the internal stress accumulated in the glaze layer can be released, thereby obtaining a complete, crack-free glaze surface. DETAILED DESCRIPTION

[0028] The present invention is further described below through specific embodiments.

[0029] A ceramic tile with imitation granite texture comprises a brick body and a matte glaze surface attached to the surface of the brick body. Specifically, the thickness of the brick body is 8-10 mm, and the thickness of the matte glaze layer is 0.5-0.6 mm.

[0030] The brick body includes the following raw materials in parts by weight: 40-50 parts of ceramic tile waste, 8-12 parts of calcite, 6-10 parts of vermiculite, 15-18 parts of andalusite, 5-10 parts of sericite, 3-5 parts of zirconium silicate, 4-7 parts of aluminum oxide, 2-3 parts of zinc oxide, and 3-5 parts of dolomite; specifically, the chemical composition of the ceramic tile waste is as follows: SiO2: 68.15%, Al2O3: 12.57%, CaO: 6.64%, MgO: 2.11%, ZnO: 7.95%, and Na2O: 2.58%.

[0031] The matte glaze includes the following raw materials in parts by weight: 7-8 parts of matte frit, 18-22 parts of perlite, 35-40 parts of quartz stone, 15-20 parts of kaolin, 3-5 parts of zirconium oxide, 6-8 parts of magnesium oxide, 1-3 parts of iron oxide, 2-3 parts of manganese oxide, and 1-2 parts of titanium oxide; specifically, the chemical composition of the matte frit is as follows: SiO2: 58.34%, Al2O3: 13.67%, CaO: 8.78%, MgO: 6.52%, ZnO: 4.08%, Li2O: 3.12%, K2O: 1.52%, Na2O: 2.17%, Fe2O3: 1.05%, and Y2O3: 0.75%.

[0032] A process for preparing ceramic tiles with imitation granite textures comprises the following steps:

[0033] Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry;

[0034] Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness;

[0035] Step 3: Apply the glaze slurry prepared in step 1 to the surface of the brick. After the glaze slurry is dried, it is sent to the kiln and fired in a reducing atmosphere at a temperature of 1120-1180°C. The firing control is as follows:

[0036] Low temperature stage: the temperature in the kiln rises from room temperature to 560-600℃, and the kiln is kept warm for 2-3 hours;

[0037] Decomposition and oxidation stage: the temperature in the kiln is raised to 880-920℃ and the kiln is kept warm for 5-6 hours;

[0038] High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1120-1180℃, and the heat preservation and kiln firing time is 10-12 hours;

[0039] Cooling and slow-release stage: the temperature in the kiln is cooled to 720-760℃ at a rate of 2℃ / min, and the kiln is kept warm for 4-6 hours;

[0040] Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

[0041] Specifically, during wet ball milling of the slurry in step 1, the raw materials are wet ground in a ball mill for 15-18 hours, the grinding medium is water, and the ratio of raw materials: balls: water is 1:1.3-1.5:1-1.5.

[0042] During the wet ball milling of the glaze slurry in step 1, the raw materials are wet ground in a ball mill for 36-42 hours, the grinding medium is water, and the ratio of raw materials: balls: water is 1:2-2.2:1.5-2.

[0043] Example 1

[0044] A ceramic tile with imitation granite texture comprises a brick body and a matte glaze surface attached to the surface of the brick body. Specifically, the brick body has a thickness of 8 mm, and the matte glaze layer has a thickness of 0.5 mm.

[0045] The brick body includes the following raw materials in parts by weight: 40 parts of tile waste, 12 parts of calcite, 6 parts of vermiculite, 18 parts of andalusite, 5 parts of sericite, 5 parts of zirconium silicate, 4 parts of aluminum oxide, 3 parts of zinc oxide, and 3 parts of dolomite.

[0046] The matte glaze includes the following raw materials in parts by weight: 7 parts of matte frit, 18 parts of perlite, 40 parts of quartz stone, 15 parts of kaolin, 3 parts of zirconium oxide, 8 parts of magnesium oxide, 1 part of iron oxide, 3 parts of manganese oxide, and 1 part of titanium oxide.

[0047] A process for preparing ceramic tiles with imitation granite textures comprises the following steps:

[0048] Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry;

[0049] Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness;

[0050] Step 3: Apply the glaze slurry prepared in step 1 to the surface of the brick. After the glaze slurry is dried, it is sent to the kiln and fired in a reducing atmosphere at a temperature of 1120°C. The firing control is as follows:

[0051] Low temperature stage: the temperature in the kiln rises from room temperature to 560℃, and the kiln is kept warm for 3 hours;

[0052] Decomposition and oxidation stage: the temperature in the kiln is raised to 880°C and the kiln is kept at this temperature for 6 hours;

[0053] High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1120℃ and the heat preservation and kiln firing time is 12 hours;

[0054] Cooling and slow-release stage: the temperature in the kiln is cooled to 760°C at a rate of 2°C / min, and the kiln is kept at this temperature for 6 hours;

[0055] Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

[0056] Specifically, during the wet ball milling of the slurry in step 1, the raw materials were wet ground in a ball mill for 15 hours, the grinding medium was water, and the ratio of raw materials: balls: water was 1:1.3:1.5.

[0057] During the wet ball milling of the glaze slurry in step 1, the raw materials were wet ground in a ball mill for 36 hours, the grinding medium was water, and the raw material: ball: water = 1:2:1.5.

[0058] Example 2

[0059] A ceramic tile with imitation granite texture comprises a brick body and a matte glaze surface attached to the surface of the brick body. Specifically, the thickness of the brick body is 10 mm, and the thickness of the matte glaze layer is 0.6 mm.

[0060] The brick body includes the following raw materials in parts by weight: 50 parts of tile waste, 8 parts of calcite, 10 parts of vermiculite, 15 parts of andalusite, 10 parts of sericite, 3 parts of zirconium silicate, 7 parts of aluminum oxide, 2 parts of zinc oxide, and 5 parts of dolomite.

[0061] The matte glaze includes the following raw materials in parts by weight: 8 parts of matte frit, 22 parts of perlite, 35 parts of quartz stone, 20 parts of kaolin, 5 parts of zirconium oxide, 6 parts of magnesium oxide, 3 parts of iron oxide, 2 parts of manganese oxide, and 2 parts of titanium oxide.

[0062] A process for preparing ceramic tiles with imitation granite textures comprises the following steps:

[0063] Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry;

[0064] Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness;

[0065] Step 3: Apply the glaze slurry prepared in step 1 to the surface of the brick. After the glaze slurry is dried, it is sent to the kiln and fired in a reducing atmosphere at a temperature of 1180°C. The firing control is as follows:

[0066] Low temperature stage: the temperature in the kiln rises from room temperature to 600℃, and the kiln is kept warm for 2 hours;

[0067] Decomposition and oxidation stage: the temperature in the kiln is raised to 920°C and the kiln is kept at this temperature for 5 hours;

[0068] High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1180℃ and the heat preservation and kiln firing time is 10 hours;

[0069] Cooling and slow-release stage: the temperature in the kiln is cooled to 720℃ at a rate of 2℃ / min, and the kiln is kept at this temperature for 4 hours;

[0070] Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

[0071] Specifically, during the wet ball milling of the slurry in step 1, the raw materials are wet ground in a ball mill for 18 hours, the grinding medium is water, and the ratio of raw materials: balls: water is 1:1.5:1.

[0072] During the wet ball milling of the glaze slurry in step 1, the raw materials were wet ground in a ball mill for 42 hours, the grinding medium was water, and the ratio of raw materials: balls: water was 1:2.2:2.

[0073] Example 3

[0074] A ceramic tile with imitation granite texture comprises a brick body and a matte glaze surface attached to the surface of the brick body. Specifically, the brick body has a thickness of 9 mm, and the matte glaze layer has a thickness of 0.55 mm.

[0075] The brick body includes the following raw materials in parts by weight: 45 parts of tile waste, 10 parts of calcite, 8 parts of vermiculite, 16 parts of andalusite, 7 parts of sericite, 4 parts of zirconium silicate, 6 parts of aluminum oxide, 2.5 parts of zinc oxide and 4 parts of dolomite.

[0076] The matte glaze includes the following raw materials in parts by weight: 7.5 parts of matte frit, 20 parts of perlite, 37 parts of quartz stone, 18 parts of kaolin, 4 parts of zirconium oxide, 7 parts of magnesium oxide, 2 parts of iron oxide, 2.5 parts of manganese oxide, and 1.5 parts of titanium oxide.

[0077] A process for preparing ceramic tiles with imitation granite textures comprises the following steps:

[0078] Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry;

[0079] Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness;

[0080] Step 3: Apply the glaze slurry prepared in step 1 to the surface of the brick. After the glaze slurry is dried, it is sent to the kiln and fired in a reducing atmosphere at a temperature of 1150°C. The firing control is as follows:

[0081] Low temperature stage: the temperature in the kiln rises from room temperature to 580℃, and the kiln is kept warm for 2.5 hours;

[0082] Decomposition and oxidation stage: the temperature in the kiln is raised to 900°C and the kiln is kept at this temperature for 5.5 hours;

[0083] High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1150℃ and the heat preservation and kiln firing time is 11 hours;

[0084] Cooling and slow-release stage: the temperature in the kiln is cooled to 735°C at a rate of 2°C / min, and the kiln is kept at this temperature for 5 hours;

[0085] Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

[0086] Specifically, during the wet ball milling of the slurry in step 1, the raw materials were wet ground in a ball mill for 16 hours, the grinding medium was water, and the ratio of raw materials: balls: water was 1:1.4:1.2.

[0087] During the wet ball milling of the glaze slurry in step 1, the raw materials were wet ground in a ball mill for 39 hours, with water as the grinding medium and a ratio of raw materials: balls: water = 1:2.1:1.8.

[0088] By optimizing and adjusting the composition and content of the matte glaze layer and combining it with a special firing process, the surface of the fired ceramic tiles has a grayish-white base color, with dotted or block-shaped black markings distributed on the base color, which is closer to the naturally formed granite texture and color, with an overall beautiful appearance and meeting market demand; among them, Zhang Hong introduced ceramic tile waste as raw material for the brick body to realize the utilization of waste resources, and combined it with sillimanite, calcium silicate and sericite to ensure the strength and wear resistance of the prepared ceramic tiles; in the matte glaze surface, zirconium oxide, iron oxide and magnesium oxide are introduced as display agents to form a bluish-white base color, and at the same time, manganese oxide is combined with titanium oxide and a firing process to form dotted or block-shaped black markings on the base color.

[0089] The above description is merely a preferred embodiment of the present invention and therefore cannot be used to limit the scope of the present invention. In other words, equivalent changes and modifications made according to the scope of the patent application and the contents of the specification should still fall within the scope of the patent of the present invention.

Claims

1. A ceramic tile imitating granite texture, characterized by: Including brick body and matte glaze attached to the surface of the brick body, The brick body comprises the following raw materials in parts by weight: 40-50 parts of tile waste, 8-12 parts of calcite, 6-10 parts of vermiculite, 15-18 parts of andalusite, 5-10 parts of sericite, 3-5 parts of zirconium silicate, 4-7 parts of aluminum oxide, 2-3 parts of zinc oxide, and 3-5 parts of dolomite; The matte glaze comprises the following raw materials in parts by weight: 7-8 parts of matte frit, 18-22 parts of perlite, 35-40 parts of quartz stone, 15-20 parts of kaolin, 3-5 parts of zirconium oxide, 6-8 parts of magnesium oxide, 1-3 parts of iron oxide, 2-3 parts of manganese oxide, and 1-2 parts of titanium oxide; The preparation process includes the following steps: Step 1: weighing and mixing the raw materials of the brick body and glaze layer according to the raw material formula, crushing, mixing and wet ball milling the powder materials to prepare the green slurry and glaze slurry; Step 2: De-ironing and sieving the slurry obtained in step 1, aging it, and then pressing it into bricks of the required specifications and thickness; Step 3: Apply the glaze slurry prepared in step 1 to the surface of the brick. After the glaze slurry is dried, it is sent to the kiln and fired in a reducing atmosphere at a temperature of 1120-1180°C. In step 3, the firing control is as follows: Low temperature stage: the temperature in the kiln rises from room temperature to 560-600℃, and the kiln is kept warm for 2-3 hours; Decomposition and oxidation stage: the temperature in the kiln is raised to 880-920℃ and the kiln is kept warm for 5-6 hours; High-fire reduction and heat preservation stage: the temperature in the kiln is raised to 1120-1180℃, and the heat preservation and kiln firing time is 10-12 hours; Cooling and slow-release stage: the temperature in the kiln is cooled to 720-760℃ at a rate of 2℃ / min, and the kiln is kept warm for 4-6 hours; Natural cooling stage: The kiln is cooled to room temperature, and the cooling time is extended to more than 12 hours.

2. The ceramic tile with imitation granite texture according to claim 1, characterized in that: The chemical composition of the matte frit is as follows: SiO2: 58.34%, Al2O3: 13.67%, CaO: 8.78%, MgO: 6.52%, ZnO: 4.08%, Li2O: 3.12%, K2O: 1.52%, Na2O: 2.17%, Fe2O3: 1.05%, and Y2O3: 0.75%.

3. The ceramic tile with imitation granite texture according to claim 1, characterized in that: The chemical composition of the tile waste is as follows: SiO2: 68.15%, Al2O3: 12.57%, CaO: 6.64%, MgO: 2.11%, ZnO: 7.95%, and Na2O: 2.58%.

4. The ceramic tile with imitation granite texture according to claim 1, characterized in that: The thickness of the brick body is 8-10 mm, and the thickness of the matte glaze layer is 0.5-0.6 mm.

5. The ceramic tile with imitation granite texture according to claim 1, characterized in that: During wet ball milling of the slurry in step 1, the raw materials are wet ground in a ball mill for 15-18 hours, the grinding medium is water, and the raw material: ball: water = 1:1.3-1.5:1-1.

5.

6. The ceramic tile with imitation granite texture according to claim 1, characterized in that: During the wet ball milling of the glaze slurry in step 1, the raw materials are wet ground in a ball mill for 36-42 hours, the grinding medium is water, and the ratio of raw materials: balls: water is 1:2-2.2:1.5-2.